510 0019 Power Tune Duals 2009 Up Instructions
User Manual: Pdf Instruction Sheets | S&S Cycle
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Instruction 510-0019 01-04-13 S&S Cycle, Inc Copyright © 2010, 2012, 2013 by S&S® Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 ® . 14025 County Highway G PO Box 215 Viola, Wisconsin 54664 Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.com All rights reserved. Printed in the U.S.A. S&S Power Tune Duals for Touring Models 2009–Up (PN 550-0004 and 550-0143) DISCLAIMER: S&S parts are designed for high performance, closed course, racing applications and are intended for the very experienced rider only. The installation of S&S parts may void or adversely affect your factory warranty. In addition such installation and use may violate certain federal, state, and local laws, rules and ordinances as well as other laws when used on motor vehicles used on public highways, especially in states where pollution laws may apply. Always check federal, state, and local laws before modifying your motorcycle. It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use, and the user shall assume all legal, personal injury risk and liability and all other obligations, duties, and risks associated therewith. The words Harley®, Harley-Davidson®, H-D®, Sportster®, Evolution®, and all H-D part numbers and model designations are used in reference only. S&S Cycle is not associated with Harley-Davidson, Inc. IMPORTANT NOTICE: Statements in this instruction sheet preceded by the following words are of special significance. WARNING Means there is the possibility of injury to yourself or others. CAUTION Means there is the possibility of damage to the part or motorcycle. NOTE Other information of particular importance has been placed in italic type. S&S recommends you take special notice of these items. WARRANTY: SAFE INSTALLATION AND OPERATION RULES: Before installing your new S&S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety. Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed. Do not smoke. Perform installation in a well ventilated area away from open flames or sparks. If motorcycle has been running, wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps. Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components. Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps. Contact S&S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S&S part on it. Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation. Use good judgment when performing installation and operating motorcycle. Good judgment begins with a clear head. Don’t let alcohol, drugs or fatigue impair your judgment. Start installation when you are fresh. Be sure all federal, state and local laws are obeyed with the installation. For optimum performance and safety and to minimize potential damage to carb or other components, use all mounting hardware that is provided and follow all installation instructions. Motorcycle exhaust fumes are toxic and poisonous and must not be breathed. Run motorcycle in a well ventilated area where fumes can dissipate. •• •• •• •• •• •• •• •• •• All S&S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve (12) months from the date of purchase. Merchandise that fails to conform to these conditions will be repaired or replaced at S&S’s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter. In the event warranty service is required, the original purchaser must call or write S&S immediately with the problem. Some problems can be rectified by a telephone call and need no further course of action. A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S&S. If it is deemed necessary for S&S to make an evaluation to determine whether the part was defective, a return authorization number must be obtained from S&S. The parts must be packaged properly so as to not cause further damage and be returned prepaid to S&S with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem, how the part was used and the circumstances at the time of failure. If after an evaluation has been made by S&S and the part was found to be defective, repair, replacement or refund will be granted. ADDITIONAL WARRANTY PROVISIONS: (1) S&S shall have no obligation in the event an S&S part is modified by any other person or organization. (2) S&S shall have no obligation if an S&S part becomes defective in whole or in part as a result of improper installation, improper maintenance, improper use, abnormal operation, or any other misuse or mistreatment of the S&S part. (3) S&S shall not be liable for any consequential or incidental damages resulting from the failure of an S&S part, the breach of any warranties, the failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of contract or duty between S&S and a customer. (4) S&S parts are designed exclusively for use in Harley-Davidson® and other American v-twin motorcycles. S&S shall have no warranty or liability obligation if an S&S part is used in any other application. ATTENTION INSTALLER (if other than owner): Please forward this instruction sheet to the purchaser of this product. These instructions also contain valuable information necessary to the end user. INTRODUCTION These instructions describe the procedure for properly installing S&S® Power Tune Duals. Review instructions carefully before beginning, as they contain important information. Please retain for future reference. All Models: NOTES: This system may not be compatible with swing arm pivot suspension stabilizers. Right side floorboard must be mounted in the lowest position. 2010 Street Glide®/Road Glide® Custom models with OEM 2-1 exhaust system will require the purchase of the following Harley-Davidson® components: 65296-95A (hanger bracket), 65724-85 (rubber isolator), 65723-85 (exhaust clamp) •• •• •• WARNING Ground and cornering clearance may be reduced. Clearance will be reduced when bikes are fitted with shorter shocks. TOOLS REQUIRED ¼ " drive ratchet 5/16" Allen wrench ¼" drive 6" extension 7/16" box wrench ¼" drive ½" socket 1/2" box wrench 3/16" Allen wrench 9/16" box wrench ¼" Allen wrench ¼" nut driver or flat screwdriver 6mm Allen wrench 10mm Allen wrench 14mm box wrench 15mm box wrench 22mm box wrench Supplies: New muffler clamps, 272 red Loctite® or equivalent, and anti-seize. PROCEDURE 1- Remove right front floorboard. 2- Remove saddlebags. 3- Remove mufflers, save clamps (Harley-Davidson® states clamps are not reusable). Tip: Use anti seize on threads of used muffler clamps. If they clamp down securely they don't need to be replaced. 4- Disconnect the O2 sensors. Remove heat shields and exhaust headers. Save the 5/16-24 hex flange port nuts. 5- Remove and save O2 sensors, retaining rings and exhaust flanges from old exhaust headers. 6- Remove the crossover pipe clamp and bracket from the transmission, these parts are not needed. Replace the socket head screws. 7- Remove the four ¼" socket head bolts closest to the rear of the oil pan (leave center rear bolt intact). These bolts are no longer needed. See the photo. 8- Remove and discard exhaust port gaskets. Install new conical gaskets. CAUTION New conical port gaskets (H-D 65324-83B) (S&S 106-5029) must be used to avoid leaks. 9- Install flanges and retaining rings on new exhaust headers. Oxygen sensors and supplied plugs/gaskets may be installed at this time. Use the supplied plugs/gaskets to cap the remaining ports. Use anti-seize on threads. 10- Install new header system using saved 5/16-24 hex flange nuts. Seat front pipe first then rear. A firm pull rearward on the rear header, while keeping the front header seated, may be necessary to clear the rear head casting. Be careful not to damage gaskets. Do not fully tighten nuts yet. 11- Install the crossover spacer weldment (counterbored side down) to the oil pan using the four 1/4-20 x 2.25" socket head cap screws and 1/4" lock washers. Important: Apply 272 Loctite to the threads and torque the fasteners to 90-108 in-lbs. 12- Install the silicone grommets and steel bushings in the crossover pipe weldment L-bracket. Install the supplied Toraca/AccuSeal pipe clamp on the expanded end of the crossover pipe weldment with the open end down and the nut facing out (cannot be installed later). 13- Position the crossover weldment under the oil pan and slide its expanded end onto the end of the front header pipe. Align the bushings in the crossover weldment L-bracket with the threaded holes in the oil pan bracket weldment. Apply 272 Loctite on the threads and loosely install the two 5/16-24 x 0.75" hex cap screws and large diameter 5/16" flat washer. 14- Install mufflers and clamps. Tip: Use anti seize on threads of the muffler clamp. Muffler rear brackets should align side to side and up and down with the saddle bag support rear mounting brackets without stress. Torque the crossover mounting screws to 20 ft-lbs. Next, torque the port flange nuts evenly. Do not tighten the muffler or crossover/header clamps until the heat shields are in place. CAUTION To ensure there are no leaks and the system is properly aligned the front and rear port nuts must be evenly torqued. 2 15- Clean header pipes and crossover (see step 21). 16- Insert worm gear clamps into slots on the back side of the heat shields. All clamp screws except the upper two on the rear shield should be positioned so the screw heads can be accessed from the front or bottom of the headers. Tip: Insert clamps halfway into the slots and bend the ends outward to ease installation over header pipes. 17- Install heat shields. Connect and loosely tighten all worm gear clamps. Position screw heads for easiest access and tighten with a ¼" nut driver or screwdriver. 18- Reinstall front floorboard in lowest position. 19- Align and tighten the muffler and header/crossover clamps. Maker sure the header/crossover clamp does not contact the frame. 20- Reconnect oxygen sensor electrical plugs. 21- Before operating motorcycle, clean pipes and mufflers with soap and water or window cleaner. Any grease or oil will permanently burn onto pipes. Dry thoroughly. CAUTION Carefully read the enclosed Important Notice sheet. Re-jetting and or recalibration may be required. WARNING Check all mounting hardware to be sure it is tight before and after first operation of motorcycle. Periodically, check tightness of all mounting hardware. USE AND CARE: Wash your accessories with the same care you use when washing your motorcycle. Use mild soap and water. DO NOT use abrasive chemicals or cleaners, or high pressure washers. CAUTION Cover ends of mufflers when washing motorcycle. Mufflers may internally corrode if saturated with water and allowed to sit. CONTENTS Description......................................... Qty Header weldment . ...................................1 Crossover weldment ...............................1 Torca/AccuSeal clamp . ...........................1 Front heat shield .......................................1 Rear heat shield .........................................1 Left heat shield ..........................................1 Heat shield clamps ................................. 10 Crossover spacer weldment..................1 ¼-20 x 2.25" oil pan bolts ......................4 Crossover spacer lock washers ............4 5/16" -24 x 0.75" hex head bolt . ..............2 5/16" flat washer.............................................2 12mm O2 plug.............................................2 12mm O2 gasket.........................................2 18mm O2 plug.............................................2 18mm O2 gasket.........................................2 5/16" washer, 1.12" OD x 0.314" ID..........2 Silicone grommet......................................2 To change up your look, replaement Heat Sheilds are also available! S&S POWER TUNE DUAL HEADERS FOR 2009–2012 BAGGERS JET-HOT® BLACK HEAT SHIELDS Part Number 2009–2012 Touring Models Replacement Heat Shields Chrome Black 3 550-0143 550-0155 550-0157
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